Joining tool for side-lapped joints

ABSTRACT

A joining tool is disclosed comprising a support; a stationary arm extending from the support at one end, the stationary arm comprising at the opposite end a first jaw; a movable arm pivotally mounted on the stationary arm; the movable arm driveable from the stationary arm in a pivotable motion by an actuator coupled to the moveable arm; and a second jaw coupled to the moveable arm, the moveable arm movable between an activated position in which the second jaw engages the first jaw and an initial position in which the second jaw is spaced from the first jaw.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to co-pendingU.S. patent application No. 13/624,237, filed on Sep. 21, 2012, andentitled “JOINING TOOL FOR SIDE-LAPPED JOINTS,” which issued into U.S.Pat. No. 10,435,890 on Oct. 8, 2019, and which claims priority to UnitedStates Provisional Patent Application Ser. No. 61/538,912 entitled“JOINING TOOL FOR SIDE-LAPPED JOINTS” filed on Sep. 25, 2011, both ofwhich are assigned to the assignees hereof and hereby expresslyincorporated by reference herein.

FIELD

The present disclosure relates generally to a tool and method forreliably fastening together side-lapped edges of adjacent deck panelsused to form flooring and roofing of buildings.

BACKGROUND

Structural steel decking is typically manufactured in thicknessesranging from 24 gauge to 16 gauge or more. The decking generally issupplied to the building site in panels ranging in size. Longitudinalribs, typically hat sections or flat-bottomed vee sections of from 1½ to7 inches in depth are formed in the panels to increase the sectionmodulus of the panels. The individual panels are typically provided withone edge having an exposed upward “male” lip. The opposite edge isprovided with a relief inverted “U” shaped (e.g., “female”) lip. Theindividual panels are joined together by placing the relief lip over themale lip and joined to form joints at periodic intervals. In manyapplications, the joints must secure the panels together so as not onlyto prevent one panel from lifting off the other, but also to prevent thepanels from shifting laterally along the seam when exposed to shearforces. By holding the panels securely enough to prevent lateralshifting, the assembled decking adds considerable membrane strength tothe finished building. Methods for attaching the side-lapped joints offluted steel deck panels are well known, and include welding,button-punching, sheet metal screws, riveting, and mechanicaldeformation of the metal forming such side-lapped joints.

In many instances, side-lapped joints of a steel deck diaphragm must beinspected for consistency and integrity before further construction of abuilding may proceed. To avoid construction delays, it is desirable toform such side-lapped joints in a manner that allows the joints to beinspected quickly and easily, preferably from the top side of thedecking.

SUMMARY

In a first embodiment, a joining tool is provided. The joining toolcomprising: a support; a stationary arm extending from the support atone end, the stationary arm comprising at the opposite end a first jaw;a movable arm pivotally mounted on the stationary arm; the movable armdriveable from the stationary arm in a pivotable motion by an actuatorcoupled to the moveable arm; and at least one mating second jaw coupledto the moveable arm, the moveable arm movable between an activatedposition in which the second jaw engages the first jaw and an initialposition in which the second jaw is spaced from the first jaw.

In one aspect of the first embodiment, the first jaw comprises at leastone male die and at least one female die arranged in spaced linearalignment in correspondence with at least one male die and female die inspaced linear alignment on the second jaw.

In another aspect, alone or in combination with any previous aspect ofthe first embodiment, the actuator is fixedly mounted on the moveablearm and extends a piston secured to the stationary arm.

In another aspect, alone or in combination with any previous aspect ofthe first embodiment, the actuator comprises a piston-and-cylinderassembly with a piston extending therefrom, the piston having an endopposite the piston-and-cylinder assembly connected to the stationaryarm, the piston extending away from the stationary arm.

In another aspect, alone or in combination with any previous aspect ofthe first embodiment, the at least one male die is arranged in spacedlinear alignment and extend transverse to a longitudinal axis of thesupport. In another aspect, the tool comprises a plurality of male diesand a plurality of female dies, the plurality of male dies arranged nspaced linear alignment and extend transverse to a longitudinal axis ofthe support.

In another aspect, alone or in combination with any previous aspect ofthe first embodiment, each male die has a generally cylindrical crosssection, each female die having a recess to receive the mating male die.

In another aspect, alone or in combination with any previous aspect ofthe first embodiment, the tool is portable and/or lightweight.

In another aspect, alone or in combination with any previous aspect ofthe first embodiment, the tool further comprises a mounted wheel supportassembly fixedly attached to the tool, the wheel assembly having one ormore wheels adapted to move between a first position in which the wheelsare in contact with decking sections for transporting the tool along thedecking seam, and a second position in which the wheels are lifted offof the decking sections when the tool is actuated.

In another aspect, alone or in combination with any previous aspect ofthe first embodiment, the actuator is a pneumatic cylinder, a hydrauliccylinder, or an electrical motor.

In another aspect, alone or in combination with any previous aspect ofthe first embodiment, the pneumatic cylinder comprises a housingcomprising a wall having a substantially circular interior crosssection; a flexible diaphragm disposed within the housing and sealedalong an outer edge thereof to the wall to divide the housing into afirst and second chamber, the first chamber having a fitting adapted toreceive a source of high pressure air, the second chamber having atleast one opening for venting the second chamber to the atmosphere, thediaphragm being adapted to be operatively attached to the piston rodpassing through the second chamber; and a spring disposed in the secondchamber for urging the diaphragm toward the first chamber.

In a second embodiment, a method of forming a side-lapping joint indecking is provided. The method comprising forming a plurality ofsheared louvers alternating in their horizontal projection along alongitudinal axis of the side-lap seam of a decking; and crimping alongone or more of a top section and/or a bottom section of the side-lappedjoint.

In one aspect of the second embodiment, the forming step and crimpingstep are performed essentially simultaneously.

In another aspect, alone or in combination with any previous aspect ofthe second embodiment, the forming step comprises the tool as defined inany of aspects of the first embodiment.

In a third embodiment, a structure comprising metal decking joined bythe method as defined in any of the aspects of the second embodiment isprovided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a first side plan view of an illustrative device in an initialstate, incorporating features of the present disclosure;

FIG. 2 is the first side plan view of an illustrative device in anactivated state, incorporating features of the present disclosure;

FIG. 3 is a perspective, reverse side view of the apparatus of FIG. 1,with exploded section of bi-controller air valve;

FIG. 4 is a partially transparent perspective view of the apparatus ofFIG. 1, shown in use on decking in accordance with the presentdisclosure;

FIGS. 5A and 5B are perspective views of jaw and die configurations inaccordance with the present disclosure;

FIGS. 5C and 5D are perspective views of an alternate jaw and dieconfiguration in accordance with the present disclosure;

FIG. 6 is a partial side view of an additional embodiment of theillustrated device of FIG. 1;

FIGS. 7 and 8 are perspective views of a portion of decking havingformed therein a structural louver in accordance with the presentinvention;

FIG. 9 is a cross-sectional view of the decking of FIG. 8 taken alongline 9-9; and

FIGS. 10-15 are first side, second side, third side, fourth side, andclose ups of the third and the fourth sides of device in its activatedstate, respectively, of the illustrative device of FIG. 1.

DETAILED DESCRIPTION

The present disclosure relates to tools for forming features in thejoints of structural steel decking and roofing commonly used incommercial construction, for example, decking used as support for pouredconcrete floors or as roofing for industrial and other buildings orstructures.

The drawing figures are intended to illustrate the general manner ofconstruction and are not necessarily to scale. In the description and inthe claims, the terms left, right, “side”, front, back, first, second,and the like are used for descriptive purposes. However, it isunderstood that the embodiment of the disclosure described herein iscapable of operation in other orientations than is shown and the termsso used are only for the purpose of describing relative positions andare interchangeable under appropriate circumstances. Throughout thepresent disclosure, the words “device” and “tool” are usedinterchangeably.

Thus, referring to FIGS. 1 and 2, FIG. 1 depicts a first side plan viewof an illustrative device in an initial state, incorporating features ofthe present disclosure. FIG. 1 depicts an initial state and FIG. 2depicts an activated state, respectively of an illustrative embodimentof tool 10 comprising a support 20 having a handle 14 adapted to begrasped by a user at about waist level so that the lower extreme of tool10 is at about foot level. Handle 14 is shown connected to the top endof the extension box 18, which in turn is connected to support 20.Handle can be of a variety of configurations, such as a bar, a tube, ora vertical pipe. Handle 14 is shown as a bar which extends transverselyto extension box 18. Handle 14 should be suitably close to the triggermechanism 102 so as to allow the operator to access the triggermechanism for the delivery of air pressure into the actuator 30 and forthe proper use of tool 10.

A conventional air valve is housed within extension box 18 and regulatesa source of pressurized air admitted through fitting 104 and provides apressurized output into hose 25 for admittance into actuator 30. Support20 may be constructed of individual plates welded together to form ahollow rectangular structure, so as to minimize weight. In anotheraspect, a hollow tube can be used for the handle 14 and/or support 20.Support 20 and/or handle 14 and/or extension box 18 can be configuredfor assembly/disassembly or be integrated together, e.g., welded, or canbe configured for adjustment of the tool's height by the user.

Still referring to FIGS. 1 and 2, the central section of support 20supports a stationary arm 72 and a first jaw 77. Stationary arm 72 canbe assembled to support 20 by conventional fastening means, such asbolts, pins, dovetails, and the like. Actuator 30 is showed attached toone end of moveable arm 70, with opposite end of arm 70 terminating atsecond jaw 75. Moveable arm 70 and actuator 30 are configured oppositethat of stationary arm 72 and corresponding second jaw 75, with movablearm 70 pivotally attached with pin 90 at the lower end of stationary arm72, so as to provide a reciprocating open and close relationship, asfurther discussed below. In the initial state, tool 10 has jaws 77, 75open, as shown in FIG. 1. In one aspect, pin 90, which functions as acentral axis bolt, can be employed with a bushing so as to minimize oreliminate heat build up, and/or wear of moving elements caused by therepetitive movement of the arm during use, thus extending the intervalbetween repair, maintenance, or replacement. The bushing can be metal,metal alloy, polymer, polymer composite, ceramic, carbon, carbon fiber,and the like. In one aspect, the bushing is bronze, oil impregnatedbronze, or brass.

Still referring to FIGS. 1 and 2, actuator 30 receives a source of airpressure from fitting 104 via flexible hose 25 which is operablyconnected to the trigger mechanism 102. FIG. 2, which depicts tool 10 inits activated state, shows moveable arm 70 moved away from stationaryarm by extended piston 41. Terminal end of piston 41 is received bypiston seat 21. Piston seat 21 is secured to stationary arm 72, causingpiston 41 to push off of stationary arm with activation of actuator 30.In the activated state, tool 10 has jaws 77, 75 closed, as shown in FIG.2. Movement of the moveable arm 70 and actuator 30 are shown by arrowsin FIG. 2.

Stationary arm 72 and/or moveable arm 70 can be of metal or non-metalplate, tube, or a cast construction. Alternatively, one or more of thehandle, support, and stationary/moveable arms can be constructed ofengineering resins or plastics, composite materials, reinforcedplastics, wood/wood composite, fiberglass, metal, or can be acombination of one or more of such materials, provided that suchmaterial construction can tolerate the expected wear and tear of thetool during use, transport, storage, and/or repair.

FIG. 3 is a perspective view of one side of tool 10 showing actuator 30directly mounted on movable arm 70, which is shown by way of cross-bar50, secured by threaded nuts and corresponding bolts. Turnbuckle 95 ispivotably secured to stationary arm 72, for example, by a clevis orsimilar engagement, as shown, through to stationary arm 72 by clevis pin28. Turnbuckle 95 pivotably secures piston seat 21, which receivesterminal end of piston 41 projecting from actuator 30. Turnbuckle 95 ispivotably mounted to stationary arm 72 so as to allow for some arc-likemotion in the stroke of piston 41. Turnbuckle 95 can also be used toadjust the length of stroke of moveable arm 70 by adjusting the positionof piston seat 21 relative to stationary arm 7. In one aspect pistonseat projects outwardly from the stationary arm in the direction ofactuator 30 so as to minimize the piston stroke distance. Alternatively,piston seat 21 can be mounted on the (out)side or face of stationary arm70 closest to actuator 30, for example, using a cross-bar or bracketmounting arrangement.

By having moveable arm 70 carry actuator 30, and having fixedlypositioned the opposite end of piston 41 in piston seat 21, total pistonstroke length is minimized, reducing the overall size of actuator neededto drive the piston, which in turn at least reduces the weight of thetool. Minimizing the stroke length can further provide for morespeed/cycle time, more power, less wear, and reduced cost ofmanufacturing. Smaller actuators allows for smaller sized piston(diameter, length), further reducing weight, cost, andreplacement/repair.

With reference to FIG. 3, stationary arm 72 is shown in an exemplaryconfiguration having two parallel extensions 72′ with theircorresponding first ends mounted to support 20 and corresponding secondends pivotably joined to moveable arm 70, respectfully, for exampleabout pin 90. Moveable arm 70 is shown in this exemplary configurationalso constructed of two parallel extensions 72′ with one pair of itscorresponding ends coupled to (or integral with) cross-bar 50 and itscorresponding opposite ends pivotably joined with ends of stationary arm72 via pin 90. The shown arrangement of the parallel extensions of thestationary and moveable arm can be reversed to that shown in FIG. 3.Alternatively, stationary arm 72 can be configured as a single extensionwith opposing side edges, with movable arm 70 having each of itsparallel extensions pivotably mounted on the opposing side edges of suchstationary arm using pin 90, for example. Other configurations ofstationary/moveable arms can be used.

As shown in exploded view 3 of FIG. 3, a bi-directional valve 120 can beoperatively disposed between fitting 104 and actuator 30 to admitpressurized air when trigger mechanism 102 is toggled and to exhaust airfrom actuator 30 when trigger mechanism 102 is released, therebyallowing actuator 30 to return to its upper limit of travel morerapidly, and thereby increasing the cycle rate of the apparatus. Asdiscussed above, cycle rate can be further improved by the combinationof bi-directional valve 120 with the shortened piston stroke, and bymounting actuator 30 on moveable arm 70.

As shown more fully in exploded view 3 of FIG. 3, bidirectional valve120 comprises a housing 122 having inlet 124 which is threaded toreceive a standard hose or tube fitting, outlet 126 which is threaded toform an airtight seal with hose 25 feeding actuator 30. Housing 122further comprises exhaust port 130 and valve seat 132 formed on theinner surface of exhaust port 130. Flexible valve member 134 isconstrained within chamber 136 of housing 122. As high pressure airenters through inlet 124, valve member 134 is forced against valve seat132 to close off exhaust port 130 and direct the flow of air throughoutlet 126 (into actuator 30). Toggling trigger mechanism 102 andterminating air flow causes air from actuator 30 to reverse directionand enter housing 122 through outlet 126. This reversed flow of airthrough outlet 126 causes valve member 134 to seat against surface 138,thereby opening exhaust port 130 to permit relatively unobstructedexhaust of pressurized air from actuator 30. Other de-pressurizingcontrols alone or in combination with the presently disclosed tool canbe used. Actuator 30 can comprise vents/openings (not shown) in itshousing to vent pressure.

In an alternate exemplary embodiment of the tool herein disclosed, oneor more wheels can be attached thereto. Thus, a wheel assemblycomprising on each side of the tool, one or more wheels coupled to, forexample, an adjustable or telescoping extension projecting from thestationary arm 72. The wheel assembly can be adapted to move between afirst position in which the wheels are in contact with decking sectionsfor transporting the tool along the decking seam, and a second positionin which the wheels are lifted off of the decking sections when the toolis to be used or actuated. The wheel assembly can comprise, among otherthings, one or more wheels configured for attachment to a stationarysupport or member arms, which in turn is attached to a telescopicadjustment member arms. Support and telescopic arms can be securedtogether by a fastener, and the support arm can be mounted to stationaryarm 72 by a bracket or other means. Other attachment configurations canbe used to mount the wheel assembly. In one aspect, a single wheelassembly can be configured, the single wheel assembly mounted to thestationary arm 72 on the opposite side of that of moveable arm 70. Forthe single wheel arrangement, the wheel can be configured with a groove,the groove a width capable of accommodating the seam of the decking(before and/or after joining), or the wheel arrangement can be twowheels spatially separated to accommodate the width of the seam in thedecking. Alternatively, or in combination, a kick-stand can be attachedto stationary arm 70 or wheel assembly so as to allow the tool to beleft in an upright or vertical position when not in use, avoidingpotential damage to actuator 30 and hose 25 when tool is otherwise leftor placed in a horizontal (laying on the surface) position.

With reference to FIG. 4, exemplary actuator 30 is shown to comprisepiston 41 inside a bore or other conventional pneumatically actuatedlinear motor. In one aspect, actuator 30 comprises a housing which isdivided into upper and lower chambers 34A and 34B by a diaphragm 36,which is crimped or otherwise sealed along the periphery of the housingof actuator 30. The center portion of diaphragm 36 is covered by apiston plate 38, which acts as a rigid surface for the pressure inchamber 34A to act upon piston 41. Actuator 30 can be configured toexert a force sufficient to form a joining in decking, at an inletpressure, for example, of 60-200 psi with a maximum stroke, for example,of about 1 to about 4 inches, or about 2 to about 3 inches, whichcorresponds to jaw movement of about 0.5 inches to about 3 inches, orabout 0.75 inches to about 2 inches for jaws having about 2 to about 5inch width, or about a 2.5 inch to about 3 inch width. Other inletpressures or stroke length can be used. Thus, when used in combinationwith the stationary arm/moveable arm as described herein, the actuator30 provides the force and displacement necessary to cut, punch, shearand/or form a louver (as described hereinafter) in virtually allstandard structural steel decking in a single-pass operation.

Again with reference to FIG. 4, piston 41 is attached to piston plate 38in order to convert the pressure action on piston plate 38 and diaphragm36 into a force for actuating the jaw mechanism as herein described.Return spring 42 acts against the pressure in chamber 34A to return thepiston plate 38 (and piston 41) to the upper limit of travel whenpressure in chamber 34A is equal to the pressure in chamber 34B, and toreturn moveable arm 70 to its initial position. As described above, thelower end of piston 41 is received by piston seat 21, the piston seatbeing secured, for example, by a turnbuckle 95 and clevis, through whichpasses a clevis pin 28.

Other mechanisms for powering the reciprocation of piston 41 to drivemoveable arm 70 can be used. The actuator used to reciprocate piston 41need not be hydraulic or pneumatic; for example, an electric motor couldalso be used to advance and retract piston 41. Within the concept of thepresent disclosure, the actuator can take a wide variety ofconfigurations. In particular, a variety of other linkages can beimplemented so as to allow for the proper movement of the moveable arm70. As used herein, the term “actuator” can also take on a wide varietyof configurations. For example, it is possible for the actuator to workby having the air supply retract the piston within the actuator 30. As aresult, through suitable linkages, the moveable arm and jaw can move inan opposite orientation to that described. Within the concept of thepresent disclosure, it is possible that hydraulics or electrics could beused in place of or cooperatively with the pneumatics described abovethat are associated with the actuator.

In normal use, when the trigger mechanism 102 is actuated, air will flowthrough inlet 104 through the air hose 25 so as to create a pushingforce on the piston within actuator 30 against the piston seat 21 onstationary arm 72. This, in turn, will move the piston 41, and themoveable arm to which it is attached, away from the stationary arm. As aresult, the moveable arm 70 as it moves away from the stationary armbring jaw 75 and its punch die/relief die toward the complementary punchdie/relief die of jaw 77 of stationary arm 72. This will cause a joiningof the adjoining deck sections located in the space between the punchdies and the relief die, as further discussed below. When the triggermechanism 102 is released by the user, spring 42 within actuator 30 willurge the piston upwardly within the actuator. This will cause piston 41,and the associated moveable arm 70, to move inwardly towards stationaryarm 72 and open the jaws.

Again with reference to FIG. 4, which depicts tool 10 in operation ondecking, as shown, tool 10 is positioned on the side-lap of the deckingwith jaws 75, 77 in an open (initial) position spanning seam 7 of femalesection 6, which overlays in an envelope male section 4. Optional wheelassembly, not shown, can either span the vee section of the decking orride in the vee section, or ride on either side of seam 7, so as toposition the tool for forming the joint. Lifting the tool, e.g., bypivoting in a direction forward from the wheel assemble positions theopposing jaws about the seam so as to lift the wheel assembly fromdecking and to prevent forward motion of the tool during activation.Upon user-activation by depressing the trigger mechanism 102, highpressure air entering actuator 30 causes extension of piston 41 andpivots moveable arm 70 and jaw 75 from its initial position and closeson jaw 77 of stationary arm 72 in its activated position to crimp, cut,punch and/or form louvers in the side seams together. Release of triggermechanism 102 by the user returns moveable arm 70 to its initialposition as described above. In one aspect, the die configuration of thetool shears through the decking material and forms louvers while alsocrimping the male/female portions of the seam, as discussed furtherbelow.

FIGS. 5A and 5B are side elevation views of an exemplary jawconfiguration. Jaw 75 which is coupled to moveable arm 70 and jaw 77coupled to stationary arm can comprise a combination of male die members(or “blades”) and female die members. Thus, jaw 75 includes one or morefemale dies 71 spatially separated by male dies 73 (or blades). Femaledies 71 can be configured as recesses in the jaw, shaped to receive thecorresponding male die of the other jaw. The female die recess can bepartially or completely through the jaw. As shown in FIGS. 5A and 5B,female dies are partially cut-outs (or reliefs) in jaws 75, 77. One orboth of jaws 75, 77 can be configured for removal from its correspondingarm for replacement. As shown, each of jaws 75, 77 comprise acombination of spatially arranged male and female dies in a cooperativearrangement for forming louvers and joining a decking.

FIG. 5C depicts an alternate exemplary arrangement of jaws/dies havingreplaceable male dies and/or other sections of the jaws. Thus, jaws 75b, 77 b which is coupled to moveable arm 70 and stationary arm 72,respectively, comprises one or more male dies 73 b, 73 c, respectively,secured to the jaws by fastener 51, which is received by die opening 53(e.g., threading or dove tail, etc.) providing for theremoval/replacement of the dies. One or more female dies 71 b, 71 c areshown as recesses being spatially separated openings between projections83 a, 83 b, through corresponding jaws 75 b, 77 b, respectively. Femaledies 71 b, 71 c can be sized to receive male dies 73 c, 73 b,respectively, to shear the side-lap for forming the joining, as furtherdiscussed below. As shown, each of jaws 75 b, 77 b comprise acombination of spatially arranged male and female dies, in a cooperativearrangement for forming the joining in a decking.

FIG. 5D depicts yet another alternate exemplary arrangement of jaws/dieshaving replaceable male dies and/or other sections of the jaws. FIG. 5Ddepicts a structure similar to that of FIG. 5C, however, fewerprojections 83 b are employed on jaw 77 c. Thus, jaw 75 c, is coupled tomoveable arm 70, and comprises three male dies 73 b, each secured to thejaw by fasteners 51, which is received by die opening 53 (e.g.,threading or dove tail, etc.) providing for the removal/replacement ofeach of the male dies (or blades). Correspondingly, jaws 77 c, which iscoupled to stationary arm 72 comprises two male dies 73 c secured to thejaw by fastener 51, as above. Two female dies 71 b on the moveable arm70, and one female die 71 c on the stationary arm 72 are shown asspatially separated openings between projections 83 a, 83 b, throughcorresponding jaws 75 c, 77 c, respectively. Female dies 71 b, 71 c canbe sized to receive male dies 73 c, 73 b, respectively, to shear (and/ordeform, and/or punch) the side-lap for forming the joining, as furtherdiscussed below. As shown, each of jaws 75 c, 77 c comprise acombination of spatially arranged male and female dies, in a cooperativearrangement for forming the joining in a decking.

In one aspect, jaws 75 b, 77 b can be of a construction having a firsthardness and one or more dies 73 b, 73 c can independently be of asecond hardness that is the same or greater than that of the firsthardness. In one aspect, dies 73 b, 73 c can independently be of asecond hardness that is greater than that of the first hardness. Thisconfiguration provides for the advantage of needing to replace only thedies and not the entire jaw, saving time and cost and/or providing forcontrolled wear of the dies.

In the exemplary alternate jaw configuration of FIG. 5C, area 79 of jaw75 b, and on opposite end adjacent die 73 b, can be sized to receivearea 81 of opposing jaw 77 b to provide a wave like crimp (or otherstructural shape) to section 170 of the decking joining. In anotheraspect, as in the exemplary alternate jaw configuration of FIG. 5D, area79 of jaw 75 c, and on opposite end adjacent die 73 b, can be configuredto receive a portion of the side-lap without a corresponding area ofopposing jaw 77 c so as to provide a wave like crimp (or otherstructural shape) to section 170 of the decking joining. Either of theseareas can comprise replaceable sections of the same or differenthardness as described above. Likewise, FIGS. 5A and 5B depict thisarrangement. In FIGS. 5A-5D, spatial separation of the male/female diescan be linear or non-linear, and can be transverse to the longitudinalaxis of the tool or parallel thereto. Height, width, length (and depthand/or width of female die), and spatial distances between each of themale/female dies can be optimized for the particular decking to beworked and the geometry and configuration of the louver desired. Variouspatterns of male/female die arrangements can be used. In one aspect,both male/female dies alternate in spatial relationship on both of thecorresponding jaws.

FIG. 6 depicts an embodiment of tool 100 useful for indexing the jawsand dies during operation of the tool on decking. Thus, FIG. 6 is apartial side perspective view showing indexer 150 of generallyrectangular shape, however, any shape can be used, such as circular,oval, square, triangular, U shape, C shape, T-shape, etc. Indexer 150 isconfigured for attachment to tool, as shown in conjunction with pin 90.Indexer 150 can be attached, for example, to stationary arm 72. Indexer150 has a surface 152 configured to contact the top of lap seam 7 of thedecking. Surface 152 (or the indexer itself) can be of a low-frictionmaterial, such as Teflon or carbon fiber, or can be of a metal, metalalloy, plastic, composite, graphite, ceramic, or the like. In use,indexer 150 provides for the distal ends of the jaws to remain slightlyabove the decking and thus, avoids scraping and/or gouging of thedecking by the motion of the jaws during activation. Indexer 150 can beconfigured to provide for a predetermined height (or clearance) of thejaws from the decking and/or lap seam. Indexer 150 can be configured forvariable height or clearance adjustment, for example, by having openingsalong its longitudinal length for attachment to the pin 90 or stationaryarm 72. One or a pair of indexers can be employed, for example, on bothsides of pin 90. Thus, in one aspect, a pair of indexers is configuredto position the distal end of the jaws 75, 77 while in the initialposition and straddling a lap seam joint between the top of the of thelap seam and its base. In this configuration, the distal end of the jawsdoes not contact or slide along the decking (or base of the lap seamjoint) when the tool is activated. In one aspect, indexer 150 adjustsand/or controls where the dies provide the louvers within the height ofthe sidelap.

FIGS. 7, 8, and 9 show perspective views of the decking after toolactivation and a sectional view of the worked area along line 9-9,respectively. As shown in FIGS. 7 and 8, the individual decking orroofing panels are typically provided with one edge having an exposedupward “male” lip 4. The opposite edge is provided with an inverted “U”shaped relief (e.g., “female”) lip 6. The individual panels aretypically joined together to form a seam 7 by placing the female lip 6over the male lip 4 and crimping the seam at periodic intervals. Thejaws of the presently disclosed tool close the seam 7 while the upsetportion formed by the die form an upset that adds lateral resistance tothe seam 7. In certain aspects, the tool and die configuration asdisclosed herein provides for a louver or louver-like joining havinglouvers projecting in opposite directions relative to line 9-9, asdepicted in FIG. 8. Configuration of tool and die disclosed hereinprovide for side-lapped joints in decking that are punched and sheared,as well as crimped by a single activation. Thus, multiple louvers,having opposing (e.g., alternating or other pattern) horizontalprojections (e.g., 160 and 168 of FIG. 9) relative to the longitudinalaxis of the decking (line 9-9) with a wave-like crimped section (e.g.,170 of FIG. 9) in proximity to upper section 7 of the side-lapping canbe formed using the tool and die configurations herein disclosed. Suchjoinings can provide superior performance attributes (e.g., shearresistance and load bearing ability) to the decking and/or to thestructure relative to other joinings having button-punching, sheet metalscrews, riveting, or other mechanical deformation joinings.

As shown in FIG. 9, which is a side view of two adjacent louvers of FIG.7 or 8, the displaced tab 160 (e.g., into page) comprising crimpedportions of lip 4 and “U” shaped lip 6 is displaced in a directionopposite the reveal portion 168 (out of page) of window 166. If seam 7is subjected to a shear loading in the direction along 9-9, thedisplaced tab 160 will bear against the reveal portion 168 of window 166in the regions indicated at 170 and 172 (upper and lower regions,respectively) reducing or eliminating prying on tab 160 or otherwiserestoring displaced tab 160 to its original configuration under suchshear loading, thus resulting in an improved joining, for example, ascompared to a button punch or screw joining. Accordingly, in order forthe seam to shift laterally, tab 160 would need to be sheared in the 9-9direction by reveal 168 of window 166. Accordingly, the shear strengthof a seam 7 sheared and upset using the joining tool herein describedhas a lateral stiffness that approaches the shear strength of thedecking material itself.

FIGS. 10 and 11 show first and second side views of tool 10 in itsinitial state, showing hose couplings 25 a, 25 b, with hose 25connecting on one end to support 20 via coupling 25 a and to actuator 30on opposite end via coupling 25 b. Support 20 has box 18 for housingconnections, trigger mechanism 102, for and threading hosing as well assupporting handle 14. FIGS. 12 and 13 show third and fourth side viewsof tool 10 in its initial state, showing turnbuckle 95 and actuator 30mounting configuration.

FIGS. 14 and 15 show close up views of the first and the second sides,respectively, of tool 10 in an activated state showing piston 41extended against seat 21 and moveable arm 70 moved from stationary arm7, with jaw 75 of moveable arm 70 in a closed relationship against jaw77 of stationary arm 72.

The aforementioned tool, in combination with jaw/die configurations, forexample, as depicted in FIGS. 5A-5D, provide for a tool capable offorming side-lapped joinings comprising sheared louvers alternating intheir horizontal projection along the longitudinal axis of the side-lapseam, and crimping along the top section (and/or bottom section) of theside-lapped joint. Such formed side-lapped joints are believed superiorto conventional joinings made by other deformations or fastenings.

Alternate cuts, punches, louvers, and combinations thereof, can be madein adjoining sections of steel decking using the tool herein describedby configuring the size, position, arrangement, and shape of theindependent male dies (or blades) and female dies of the opposing jawsin the tool described herein. The tool can be configured so that thedeck sections are loosely connected together or more rigidly connected.The shape of the cuts, punches, and/or louvers can be suitably shapedand/or arranged for providing joinings that substantially preventlateral shifting of the sections with respect to each other or frompulling away from each other. Shapes of the cuts, punches, or louverscan be, for example, round, square, rectangular, and/ortriangular-shaped. The crimping formed by the tool herein described canalso impart a wave-like appearance and/or other pattern in the joinedsection, for example, at top region 170 of the joining.

In another aspect, buildings with improved structural attributesconstructed with steel decking joined using the tool and/or dieconfigurations described herein are provided. The tool design (weight,speed, power, die replacement, etc.) may provide faster and less laborintensive construction. The die configuration and resulting louverjoints formed in the steel decking is believed capable of providingadditional strength and rigidity to the structure, reducing oreliminating re-working of sections of the structure after inspectionand/or unexpected stresses imparted to the decking during or afterconstruction.

By avoiding two pivoting arms, the total stroke distance between thestationary/moveable arms can be minimized. In addition, since thewearing of the pivotal connections will only occur with respect to asingle arm, maintenance of the present tool will be less than thatassociated with a pair of pivotable arms. The minimizing of the linkagesresults in less cost and in greater precision in the manufacturing ofthe tool. It is further believed that the minimization of linkagesinvolved in the movement of the moveable arm will give greater longevityand reliability to the tool and in the formation of the joinings.Moreover, the disclosed tool includes a replaceable die assembly thatprovides not only for rapid replacement but for equalizing the wear onthe dies, thereby avoiding excessive stress on any particular die, andextending the usable life of the tool and the quality of the joint madeby the tool. In addition, providing replaceable male member dies on thejaws without requiring removal of the jaws from the tool will reducedown time and replacement/tooling costs for the end-user. Thecombination of male and female dies on each of the jaws of thestationary/moveable arms provides a unique louver structure comprisingboth shearing and crimping that is believed to result in side-lappedseam joints of higher horizontal shear loading values, and moreresistance to slippage when subjected to a horizontal load than of othertools.

Those skilled in the art will now appreciate that an improved punchingtool has been described for forming an attachment in an interlockingside-lapped seam of a steel deck structure which provides a solidattachment capable of resisting significant horizontal shear loads. Thedisclosed punching tool can be operated relatively quickly and easily bya deck installer to attach interlocking side-lapped seams of a steeldeck structure. The design of the tool is capable of lightweightconstruction reducing fatigue and/or injury to the user. The resultingside-lap attachment can be quickly and easily inspected by an inspectorstanding atop the assembled steel decking.

While the present disclosure has been described with respect topreferred embodiments thereof, such description is for illustrativepurposes only, and is not to be construed as limiting the scope of theinvention. Various modifications and changes may be made to thedescribed embodiments by those skilled in the art without departing fromthe true spirit and scope of the invention as defined by the appendedclaims.

What is claimed is:
 1. A joining tool comprising: a support; astationary arm extending from the support at one end, the stationary armcomprising at an opposite end a first jaw; a moveable arm pivotallymounted on the stationary arm, the moveable arm comprising a second jaw;an actuator fixedly mounted on the moveable arm, wherein the actuatorcomprises a piston operatively coupled to the stationary arm and theactuator; wherein the moveable arm is driveable from the stationary armin a pivotable motion by the actuator and wherein the actuator moveswith the moveable arm; and wherein the moveable arm is moveable betweenan activated position in which the second jaw engages the first jaw andan initial position in which the second jaw is spaced from the firstjaw.
 2. The tool of claim 1, wherein the first jaw comprises at leastone first male die and at least one first female die arranged in spacedlinear alignment in correspondence with at least one second male die andat least one second female die arranged in spaced linear alignment onthe second jaw.
 3. The tool of claim 2, comprising a plurality of firstand second male dies and a plurality of first and second female dies,both of which are arranged in spaced linear alignment, the plurality offirst and second male dies extending transverse to a longitudinal axisof support.
 4. The tool of claim 2, wherein the at least one first maledie and the at least one second male die each have a generallycylindrical cross section, and the at least one first female die and theat least one second female die each have a recess to receive mating maledies.
 5. The tool of claim 1, wherein the actuator comprises apiston-and-cylinder assembly with the piston extending therefrom, thepiston having an end opposite the piston-and-cylinder assembly connectedto the stationary arm, the piston extending away from the stationaryarm.
 6. The tool of claim 1, wherein the piston is generallyperpendicular with the stationary arm when in a retracted position. 7.The tool of claim 1, further comprising at least one indexer configuredto contact decking while the stationary arm and the moveable armstraddle a side-lap seam and position the first jaw and the second jawbetween a top of the side-lap seam and a base of the side-lap seam whilein the initial position, and wherein the at least one indexer contactsthe decking before the stationary arm or the moveable arm contact thedecking.
 8. The tool of claim 7, wherein the at least one indexer isconfigured for adjustment in order to contact the decking to space thestationary arm or the moveable arm from the top of the side-lap seam. 9.The tool of claim 1, wherein the actuator is a pneumatic cylinder, ahydraulic cylinder, or an electrical motor.
 10. The tool of claim 9,wherein the pneumatic cylinder comprises: a housing comprising a wallhaving a substantially circular interior cross section; a flexiblediaphragm disposed within the housing and sealed along an outer edgethereof to the wall to divide the housing into a first and secondchamber, the first chamber having a fitting adapted to receive a sourceof high pressure air, the second chamber having one or more openings forventing the second chamber to an atmosphere, the diaphragm being adaptedto be operatively attached to the piston passing through the secondchamber; and a spring disposed in the second chamber for urging thediaphragm toward the first chamber.
 11. The tool of claim 1, furthercomprising: a bi-directional valve operatively coupled to the actuator.12. The tool of claim 1, further comprising: a piston seat operativelycoupled to the stationary arm; and wherein the piston is operativelycoupled to the stationary arm through the piston seat.
 13. The tool ofclaim 12, wherein the piston seat is located on a face of the stationaryarm closest to the actuator.
 14. The tool of claim 12, wherein thepiston seat projects outwardly from the stationary arm towards theactuator.
 15. A joining tool comprising: a support; a stationary armextending from the support at one end, the stationary arm comprising atan opposite end a first jaw; a moveable arm pivotally mounted on thestationary arm, the moveable arm comprising a second jaw, wherein themoveable arm is driveable from the stationary arm in a pivotable motionby an actuator between an activated position in which the second jawengages the first jaw and an initial position in which the second jaw isspaced from the first jaw; and at least one indexer operatively coupledto the support, the stationary arm or the moveable arm, wherein the atleast one indexer is operatively configured to contact decking while thefirst jaw of the stationary arm and the second jaw of the moveable armstraddle a side-lap seam and position the first jaw and the second jawbetween a top of the side-lap seam and a base of the side-lap seam whilein the initial position, and wherein the at least one indexer contactsthe decking before the first jaw of the stationary arm or the second jawof the moveable arm contact the decking.
 16. The tool of claim 15,wherein the at least one indexer is configured for adjustment in orderto contact the decking to space the stationary arm or the moveable armfrom the top of the side-lap seam.
 17. The tool of claim 15, wherein thedecking contacted by the indexer is the top of the side-lap seam.